Modular building system

ABSTRACT

There is provided a panel for use in the construction of a structure. The panel includes a panel body defining a panel body periphery. The panel body additionally includes a panel body front surface and an opposing panel body back surface. A flange extends along the panel body periphery. The panel further includes an elongate rib having first and second rib walls and a rib channel. The first and second ribs walls extend from and along the panel body back surface. The rib channel is disposed between and along the first and second ribs walls and extends toward the panel body back surface. The rib channel defines a rib longitudinal axis generally parallel to the adjacent panel body back surface. The panel is cuttable along the rib channel to form a structural element. A plurality of structural elements may be combined to form the structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 11/977,026 entitled MODULAR BUILDING SYSTEM filed Oct. 23, 2007, all of the teachings of which are incorporated herein by reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

(Not Applicable)

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a modular construction system and more particularly, to a modular panel system including panels that are configurable to quickly construct a low-cost and durable structure.

2. Description of the Related Art

It is well known that the construction of a structure can be a very time consuming and expensive endeavor. The planning and design of the structure can be as long, if not longer than the actual construction itself. As such, many construction projects can take several months or years to complete. Such lengthy and costly construction projects are common in relation to residential and commercial construction.

Although the planning and cost associated with the above-mentioned construction typically yields a structure specifically tailored to the desires of the individual builder, certain types of structures generally do not require the same amount of planning and construction time. Rather, many structures simply require four walls and a roof. Exemplary structures may include storage facilities, warehouses, garages, patio enclosures, and the like.

Furthermore, a long and costly construction project may not be feasible in certain situations. Rather, a quickly constructed temporary structure may be needed. For example, emergency medical treatment facilities may be needed after a natural disaster, or in battlefield environments. Additionally a temporary gathering of large groups of people may also present a need for a temporary structure.

Known structures that are commonly used under such circumstances include tents, mobile structures, and the like. Tents are very easily and quickly assembled, however, they offer very minimal structural protection. Most tents are not rigid and thus, may not offer a great deal protection from the elements (e.g., snow, sleet, hail, etc.). Mobile structures may offer more structural support; however, they may be limited in their adaptability to conform to the particular needs and desires of the owner.

As is apparent from the foregoing, there exists a need in the art for a modular system which may be used to quickly assemble a rigid structure and is highly adaptable to construct a structure according to the desired specifications of the owner. The present invention address this particular need, as will be discussed in more detail below.

BRIEF SUMMARY OF THE INVENTION

The present invention specifically addresses and alleviates the above-identified deficiencies in the art. In accordance with an embodiment of the present invention, there is provided a multifunctional panel for use in the construction of a structure. The panel includes a panel body defining a panel body periphery. The panel body additionally includes a panel body front surface and an opposing panel body back surface. A flange extends along the panel body periphery. The panel further includes an elongate rib having first and second rib walls and a rib channel. The first and second ribs walls extend from and along the panel body back surface. The rib channel is disposed between and along the first and second ribs walls and extends toward the panel body back surface. The rib channel defines a rib longitudinal axis that is generally parallel to the adjacent panel body back surface. The panel is cuttable along the rib channel to form a structural element. A plurality of structural elements may be combined to form the structure.

It is contemplated that a plurality of like panels may be connected to quickly and economically construct a structure. In this manner, respective ones of the plurality of panels may be cut along the rib channel to form the various structural characteristics of the resultant structure (e.g., window opening, entryway, roof gable, etc.). The rib channels may provide a guide along which the panels may be cut. The resultant structure may be used as a temporary structure, or for low cost housing, patios, garages, storage buildings, and the like.

According to various embodiments, the panel may include a plurality of elongate ribs. The longitudinal axes of the plurality of ribs may be parallel, or angularly positioned relative to each other, thereby resulting in intersecting ribs. The panels may be cut along one or multiple rib channels to form an individual structural element.

Furthermore, the panel may be formed of a variety of materials. The materials may include, but are not limited to, structural foam or a plastic material. The structural foam may include at least one recycled polymer, thereby providing a more environmentally and economically friendly panel material.

The panels may be used in connection with a connecting rail. The connecting rail may facilitate connection of one panel to another. The connecting rail includes a first connector channel and a second connector channel. The first and second connector channels are each configured to engage with the flange of a respective panel. A fastener may be used to attach the flange of a respective panel to the connecting rail. The connecting rail may be configured to engage with two panels, wherein each panel defines a panel plane disposed parallel with respect to each other. Alternatively, the connecting rail may be configured to engage with two panels, wherein each panel defines a panel plane disposed angularly with respect to each other.

The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings in which like numbers refer to like parts throughout and in which:

FIG. 1 is a front perspective view of a panel configured for use in the construction of a structure;

FIG. 2 is a rear perspective view of the panel illustrated in FIG. 1, the panel having a plurality of elongate ribs extending from and along a panel body back surface, each rib including first and second rib walls and a rib channel;

FIG. 3A is a cross-sectional view of an elongate rib, wherein first and second rib wall distances are greater than a rib channel depth;

FIG. 3B is a cross-sectional view of an elongate rib, wherein the first and second rib wall distances are equal to the rib channel depth;

FIG. 3C is a cross-sectional view of an elongate rib, wherein the first and second rib wall distances are less than the rib channel depth;

FIG. 4 is a front elevation view of the panel illustrated in FIG. 1;

FIG. 5 is a side view of the panel illustrated in FIG. 4;

FIG. 6 is a rear elevation view of the panel illustrated in FIG. 4;

FIG. 7 is a top view of the panel illustrated in FIG. 4;

FIG. 8 is an exploded top view a panel assembly including two panels and a connecting rail, the connecting rail having first and second connector channels;

FIG. 9 is a top view of the panels and connecting rail shown in FIG. 8, wherein the panels are engaged with the first and second connector channels, the panels defining planes disposed parallel with respect to each other;

FIG. 10 is a top view of the panels and connecting rail shown in FIG. 8, wherein the panels are engaged with the first and second connector channels, the panels defining planes disposed angularly with respect to each other;

FIG. 11 illustrates three panels, each having a plurality of ribs, each panel being cuttable along the ribs to collectively form a roof gable;

FIG. 12 illustrates two panels, each panel having a plurality of ribs, each panel being cuttable along the ribs to form a portion of a wall having an entryway and a window;

FIG. 13 is a perspective view of a structure constructed from a plurality of panels; and

FIG. 14 is a sectional view of a panel constructed from structural foam.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes of illustrating a preferred embodiment of the present invention only, and not for purposes of limiting the same, FIG. 1 depicts a panel 10 constructed in accordance with the present invention. It is contemplated that the panel 10 may be used in the construction of a structure. More specifically, a plurality of panels 10 may be used to construct the structure. Each panel 10 includes a panel body 12 defining a panel body periphery 14. The panel 10 includes a flange 20 extending along the panel body periphery 14. The panel body 12 includes a panel body front surface 16 and a panel body back surface 18. The panel body front surface 16 may be textured to simulate several different construction surfaces. For instance, the front surface 16 may be textured to simulate a stucco surface, a brick or stone surface, or other textures known by those having skill in the art. In the particular embodiment shown in FIG. 1, the panel body front surface 16 includes a smooth, flat surface.

FIG. 2 illustrates the panel body back surface 18. The panel 10 includes a plurality of elongate ribs 22 extending from the panel body back surface 18. FIGS. 3A-3C illustrate a cross-sectional views of a rib 22. The rib 22 includes a first rib wall 21 and a second rib wall 23. A rib channel 25 is disposed between and along the first and second rib walls 21, 23. The rib channel 25 also extends toward the panel body back surface 18. The rib channel 25 defines a rib longitudinal axis 27 generally parallel to the adjacent panel body back surface 18.

The first rib wall 21 extends from the panel body back surface 18 a first rib wall distance d₁ and the second rib wall 23 extends from the panel body back surface 18 a second rib wall distance d₂. The rib channel 25 extends toward the panel body back surface 18 to define a rib channel depth d₃. According to various embodiments, the first rib wall distance d₁, the second rib wall distance d₂, and the channel depth d₃, may vary. In the embodiments shown in FIG. 3A-3C, the first and second rib wall distances d₁, d₂ are equal. However, it is understood that the first rib wall distance d₁ may differ from the second rib wall distance d₂. FIG. 3A illustrates a rib 22 wherein the rib channel depth d₃, is less than the first and second rib wall distances d₁, d₂, thereby resulting in a relatively shallow rib channel 25. This may enhance the structural rigidity of the panel 10, as there is more support under the rib channel 25. However, it may be more difficult to cut the panel 10 along the rib channel 25 if the rib channel 25 is relatively shallow. FIG. 3B depicts a rib 22 wherein the rib channel depth d₃ is equal to the first and second rib wall distances d₁, d₂. It may be easier to cut the panel 10 shown in FIG. 3B, rather than the panel 10 depicted in FIG. 3A; however, the panel 10 in FIG. 3B may not offer as much support as the panel 10 in 3A. FIG. 3C shows a rib 22 wherein the rib channel depth d₃ is greater than the first and second rib wall distances d₁, d₂, thereby resulting in a relatively deep rib channel 25. This may facilitate the cutting of the panel 10; however, as discussed above, it may result in a weaker panel 10.

The panel 10 may be cuttable along the rib channel 25 to configure the panel 10 as required by the builder. In other words, the panel 10 may be configured to define the structural characteristics of the structure. For instance, the panels 10 may be configured to define a window opening, entryway, skylight, or roof gable, among other structural characteristics, as described in more detail below. Although the panels 10 are cuttable along the ribs 22, it may be desirable to use the entire panel 10 without cutting it. An entire panel 10 may be used to form a portion of a wall.

According to another embodiment, the panel 10 includes at least one multi-channel rib 24. A multi-channel rib 24 is similar to the rib 22 described above, however the multi-channel rib 24 includes more than one rib channel 25. The panels 10 depicted in FIGS. 2 and 6 include three multi-channel ribs 24, each having two rib channels 25. Such ribs 24 include first, second, and third multi-channel rib walls. A primary channel is disposed between the first and second multi-channel rib walls, and a secondary rib channel is disposed between the second and third multi-channel rib walls. The panel 10 may be cut along a rib 22 having a single rib channel 25 or along a multi-channel rib 24 having primary or secondary rib channels. Multi-channel ribs 24 may provide additional structural support to the panel 10, as there is at least one additional rib wall. In the embodiment shown in FIGS. 2 and 6, multi-channel ribs 24 are disposed along the longitudinal edges of the panel body 10, as well as along the longitudinal centerline of the panel body 10. However, such ribs 24 may be disposed anywhere on the panel body 10.

Another implementation of the invention includes a boarder member 26 extending from and along the panel body back surface 18. The boarder member 26 and ribs 22, 24 extend from the panel 10 in like manner; however, the boarder member 26 does not include a rib channel. It may be desirable to position the boarder member 26 along the panel body periphery 14 to form a boarder thereabout. As shown in FIGS. 2 and 6, the boarder member 26 and multi-channel ribs 24 collectively form a boarder around the panel body periphery 14. However, it is understood that the boarder member 26 may be located anywhere along the panel body back surface 18.

FIGS. 4-7 best illustrate the flange 20 extending from the panel body periphery 14. As shown, the flange 20 extends around the entire panel body periphery 14, although various embodiments may include a flange 20 that only extends from a portion of the panel body periphery 14. For instance, the flange 20 may only extend along lateral edges of the panel 10 or longitudinal edges of the panel 10. The flange 20 extends from the panel body periphery 14 a flange distance “F.” The flange distance F may be uniform, as illustrated in FIGS. 4-7, or the panel 10 may include a flange 20 defining a variable flange distance F.

The panels 10 may be configured in a variety of different shapes and sizes. Although the panels 10 shown in the drawings are rectangular in shape, it is contemplated that the panels 10 may be configured to be any shape. Furthermore, various embodiments of the present invention include panels 10 that vary in size; although one particular embodiment includes panels 10 that are 3′×9′×4″.

It is contemplated that the panels 10 may be constructed from a variety of different materials. One aspect of the invention includes fabricating the panels 10 from molded structural foam. Consequently, the panel 10 is molded within a mold cavity. A polymer resin is injected at low pressure and slow speed to create a structural foam that fills within the mold cavity. With respect to the polymer resin, it is contemplated that any of a wide variety of polymers may be chosen, as well as combinations thereof, to thus impart desired features to the panel 10. In this regard, by selecting polymers having known characteristics, the panel 10 may be formed to have a desired impact resistance, resistance to temperature extremes, desired strength/tension properties, resistance to various types of chemicals, as well as desired aesthetic features, such as color, shape and the like. Exemplary of the types of polymers suitable for use in the structural foam molding process include commercially available polyolefins such as polypropylene and polyethylene, including high density polyethylene (HDPE) and low density polyethylene (LDPE). Such polymers may possess the characteristic of having a melt flow index within the range of ML 30-70. By virtue of utilizing such polymers, it is contemplated that the panel 10 may be fabricated from recycled materials, as will be readily understood by those skilled in the art. Indeed, any component of the panel 10 fabricated from the structural foam molding process will itself be recyclable to thus enable the panel 10 to not only be formed from recycled materials, but be recyclable themselves. Still further, by virtue of being fabricated from a specific type of polymer material, the panel 10 will likely never require painting and any color will be inherent through the polymer material.

With respect to the parameters under which the structural foam molding processed is achieved, it is contemplated that the polymer resin will be injected into the mold cavity at a pressure of around 3000 to 1800 PSI at a rate of 30 kilograms per second. According to a particular embodiment, the polymer will be injected at a pressure of approximately 2000 PSI at a speed from 30 kilograms per second to 50 kilograms per second. Forming the panel 10 from structural foam according to the aforementioned process results in very little built-in stress and virtual freedom from environmental stress, cracking, and not to mention greatly improved tolerance to age, environmental factors, rough usage and general wear.

By virtue of using the structural foam molding process, panels 10 may be formed that are larger and sturdier than like components fabricated from wood, metal, concrete and fiberglass. Panels 10 constructed from structural foam may include a cellular foamed core 28 surrounded by a rigid outer skin 30, as best illustrated in FIG. 14. Moreover, the panels 10 formed from the structural foam molding process are substantially more sound structurally, nearly stress-free, can be formed to be thicker, sturdier and possess substantially minimal warpage compared to prior art materials.

Although the foregoing describes fabricating the panels 10 with structural foam, it is understood that other materials known by those having skill in the art may also be used without departing from the spirit and scope of the present invention.

It is contemplated that a plurality of panels 10 may be combined to form a structure. According to one embodiment, the panels 10 are connected via a connecting rail 34. FIGS. 8-10 show various embodiments of a panel assembly 32 including two panels 10 and a connecting rail 34. The connecting rail 34 includes a first connector channel 36 and a second connector channel 38. The first and second connector channels 36, 38 are each configured to engage with the flange 20 of a respective panel 10. According to one embodiment, the panels 10 engage with the connecting rail 34 such that a portion of the panel body 12 is abutting a contact surface 31 of the connection rail 34.

Each panel 10 defines a panel plane. The connecting rail 34 may be configured to engage with panels 10 defining panel planes that are parallel to each other. The connecting rail 34 may also be configured to engage with panels 10 defining planes that are angularly disposed with respect to each other. In the embodiment shown in FIGS. 8-9, the first and second channels 36, 38 are configured to engage with panels 10 defining panel planes that parallel to each other. In the embodiment depicted in FIG. 10, the connecting rail 34 is configured to engage with panels 10 defining panel planes that are angularly disposed relative to each other. Furthermore, the panels 10 may be secured to the connecting rail 10 via a fastener 40. The fastener 40 may include a screw, rivet, or other fastener known by those skilled in the art.

The panels 10 may be cut along the ribs 22 to form the various structural characteristics of the structure. For instance, the panels 10 may be cut to form an entryway, window opening, angled roof gable, and the like. FIG. 11 illustrates a roof gable 42 constructed from a plurality of panels 10. Three panels 10 are illustrated in FIG. 11. Each panel 10 is cut along a cut-line to collectively form the roof gable 42. One panel 10 is cut to form a crest 50 of the roof gable 42, and two additional panels 10 are cut to form the sloping side 52 of the roof gable 42. More specifically, one panel 10 is cut along a first cut-line 48 to form the crest 50 of the roof gable 42. The panel 10 is cut along the first cut-line 48 to define a first gable portion 50 and a first remainder portion 52. Another panel 10 is cut along a second cut-line 54 to define a second gable portion 56 and a second remainder portion 58. The second cut-line 54 defines a slope that compliments the slope of the first cut-line 48. In this regard, the slope of the second cut-line 54 may be identical to the slope of the first cut line 48. An additional panel 10 is cut along a third cut-line 60, which defines a third gable portion 62 and a third remainder portion 64. The slope of the third cut-line 60 may be identical to the slope of the first and second cut-lines 48, 54. The first, second and third gable portions 50, 56, 62 are used to construct a portion of the roof gable 42. The first, second and third remainder portions 52, 58, 64 may be used to construct other areas of the structure. Although not shown, additional panels 10 would be cut along similar cut-lines to form the other sloping side 52 of the roof gable 42.

Referring now to FIG. 12, there is shown a wall 54 constructed from five panels 10. Two of the five panels 10 are cut along rib channels 22 to form an entryway 68 and a window opening 74 within the wall 66. One panel 10 is cut along an entryway cut-line 67 to define a door portion 70 and an overhead portion 72. The overhead portion 72 is placed over the entryway 68. The door portion 70 may be left out of the entryway 68, or, it may be hingedly connected to the connecting rail 34 to form a door within the entryway 68.

Another panel 10 is cut to define a window opening 74 within the wall 66. The panel 10 is cut along a lower window cut-line 78 and an upper window cut-line 80 to define a lower window portion 76, an upper window portion 82, and a window remainder portion 84. The upper window portion 82 is placed over the window opening 84 and the lower window portion 76 is placed under the window opening 74. The window remainder portion 84 may be used to form other portions of the structure.

Although the above relates to using the panels 10 to form walls, roof gables 42, entryways 68 and window openings 74, it is understood that the panels 10 may be used to form other structural characteristics known by those skilled in the art. For instance, the panels may also be used to form a skylight within a panel 10 used to construct a portion of the roof.

Referring now to FIG. 13, there is shown a structure 86 constructed from a plurality of panels 10. The structure 86 includes two roof peaks 88, each having two roof gables 42, an entryway 68 with a door 70, and a plurality of window openings. The structure 86 includes both vertical and horizontal window openings 90, 92. In the particular embodiment shown in FIG. 13, the vertical window opening 90 may be formed from one panel 10. In other words, one panel 10 may be cut along upper and lower window cut-lines 80, 78 to form the vertical window 90. Conversely, the horizontal window openings 92 span across multiple panels 10. Therefore, at least two panels 10 may be similarly cut to form a horizontal window opening 92.

The panels 10 may be quickly and easily connected via connecting rails 34 to form the structure 86, as desired by the builder. The size of the structure 86 may easily be expanded or reduced by adding or removing panels 10. The structure 86 may be used as an emergency trauma center in the case of a natural disaster, or to treat the wounded as the return from the battlefield. The structure 86 may alternatively be used as a storage facility or a car port. In addition, a builder may use the panels 10 to construct a structure 86 for entertainment purposes, such as a patio enclosure. Furthermore, the panels 10 may be used to construct temporary structures, such as temporary classrooms, and the like. In this regard, the panels 10 may be used to quickly and efficiently construct a wide range of structures 86.

The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. 

1. A panel for use in the construction of a structure, the structure being formed of a plurality of structural elements, the panel comprising: a panel body defining a panel body periphery, the panel body including a panel body front surface and an opposing panel body back surface; a flange extending along the panel body periphery; and an elongate rib having first and second rib walls and a rib channel, the first and second ribs walls extending from and along the panel body back surface, the rib channel disposed between and along the first and second ribs walls and extending toward the panel body back surface, the rib channel defining a rib longitudinal axis generally parallel to the adjacent panel body back surface, the panel being cuttable along the rib channel to form a respective one of the plurality of structural elements.
 2. The panel as recited in claim 1, wherein the first rib wall extends from the panel body back surface a first rib wall distance, the second rib wall extends from the panel body back surface a second rib wall distance, and the rib channel extends toward the panel body back surface to define a rib channel depth.
 3. The panel as recited in claim 2, wherein the first rib wall distance, the second rib wall distance and the channel depth are equal.
 4. The panel as recited in claim 2 wherein the first rib wall distance is equal to the second rib wall distance, and the rib channel depth is less than the first and second rib wall distances.
 5. The panel as recited in claim 1, wherein the panel is formed of structural foam.
 6. The panel as recited in claim 5, wherein the structural foam includes at least one polymer.
 7. The panel as recited in claim 6, wherein the polymer is a recycled polymer.
 8. The panel as recited in claim 1, wherein the panel is formed of a plastic material.
 9. The panel as recited in claim 1 further comprises a plurality of elongate ribs.
 10. The panel as recited in claim 9, wherein at least two of the plurality of elongate ribs intersect.
 11. The panel as recited in claim 1 wherein the panel is rectangular.
 12. A panel assembly for use in the construction of a structure, the panel assembly comprising: at least two panels, each of the at least two panels comprising: a panel body defining a panel body periphery, the panel body including a panel body front surface and an opposing panel body back surface; a flange extending along the panel body periphery; and an elongate rib having first and second rib walls and a rib channel, the first and second ribs walls extending from and along the panel body back surface, the rib channel disposed between and along the first and second ribs walls and extending toward the panel body back surface, the rib channel defining a rib longitudinal axis generally parallel to the adjacent panel body back surface, the panel being cuttable along the rib channel to form a respective one of the plurality of structural elements; and a connecting rail disposed between the at least two panels, the connecting rail having a first connector channel and a second connector channel, the first and second connector channels each being configured to engage with the flange of a respective panel.
 13. The panel assembly as recited in claim 12 wherein each of the at least two panels define a panel plane disposed parallel with respect to each other.
 14. The panel assembly as recited in claim 12 wherein each of the at least two panel panels define a panel plane disposed angularly with respect to each other.
 15. The panel assembly as recited in claim 12 further comprising a fastener configured to attach the flange of a respective panel to the connecting rail.
 16. The panel assembly as recited in claim 12, wherein each of the at least two panels is formed of structural foam.
 17. The panel assembly as recited in claim 16, wherein the structural foam includes at least one polymer.
 18. The panel assembly as recited in claim 17, wherein the polymer is a recycled polymer.
 19. The panel assembly as recited in claim 12, wherein each of the at least two panels is formed of a plastic material.
 20. The panel assembly as recited in claim 12, wherein each of the at least two panels further comprises a plurality of elongate ribs. 